Method of casting cementitious shingles on a sloping roof



DCC- 7, 1965 c. wooDwoRTH METHOD OF CASTING CEMENTITIOUS SHINGLES ON ASLOPING ROOF Original Filed May 22. 1961 IN VEN TOR. CHQ/201.4. L.waowan ng United States Patent O 3,222,436 METHOD OF CASTINGCEMENTITIOUS SHINGLES ON A SLOPING ROF Carroll L. Woodworth, Glendale,Ariz., assignor to Ari- Zonolite Co., Glendale, Ariz., a corporation ofIllinois Original application May 22, 1961, Ser. No. 111,548.

Divided and this application Apr. 29, 1963, Ser. No.

6 Claims. (Cl. 264-34) This application is a division of my co-pendingapplication Serial No. 111,548, tiled May 22, 1961, now Patent No.3,179,999, granted April 27, 1965.

My invention relates to a method of forming a roof surface on a slopingsupport surface by casting roof tiles of cementitious material in situon such support surface in adjacent positions.

It is an object of the invention to cast in place a lateral series ofcementitious tiles on adjoining areas of a lateral band of the supportsurface, starting at an upper elevation and progressing to bands atlower elevations.

Another object is to form a roof surface by casting tiles in place on anirregulator or knobby support surface so as to lock thereto and requireno other attachment to the sloping support surface. In this connectionit is an object to form relatively large tiles, usually rectangular, ofsufficient thickness to be held in place substantially exclusively bytheir weight and their interlock with the knobby support surface.

A further object is to provide a roof forming method in which the tilesas cast or as subsequently scored are substantially independent of eachother in the sense that each tile can expand and contract independentlyof adjoining tiles whereby expansion and contraction will not tear ordestroy the waterproof support surface therebeneath.

Another object is to provide a pouring method that provides a spill-outspace producing a spill-out portion of the cementitious materialextending into the zone of a subsequently cast tile. A further object isto cast the subsequent tile over such spill-out portion.

Still another object is to provide a pouring method which scorespreviously-cast but yet-unset cementitious material at one or morepositions adjacent the periphery of each tile, this scoring being to adepth near or to the support surface.

A further object is to provide such a pouring method that will castBermuda-type tiles thicker at their lower edges than at their upperedges so as to expose a portion of the former to the weather along thecommon boundary of two lateral courses and provide a lateral shadowline.

Another object is to cast tiles in areas of a support surface adjoiningprecast peripheral tiles at the ends of a lateral course. A furtherobject is to make possible, if desired, the pouring of cementitiousmaterial in covering relationship with a precast peripheral tile.

Further objects and advantages will be apparent to those skilled in theart from the following description of exemplary embodiments of theinvention.

Referring to the drawing:

FIG. 1 is a perspective View of a small roof area showing the precastperipheral tiles in position;

FIG. 2 is a perspective view of a pouring form of the invention used incasting a majority of the tiles in a course;

FIG. 3 is a sectional view of a roof showing the pouring form of FIG. 2in use in casting the tiles of a second course below a previously-castcourse, the pouring form being shown in section as taken along the lines3 3 of FIG. 2;

FIG. 4 is a perspective view of another pouring form ice of theinvention, usually employed at the end of a course; and

FIG. 5 is a view similar to FIG. 3 showing the pouring form of FIG. 4 inuse in casting the end ltile of a second course, the pouring form beingshown in section as taken along the lines 5-5 of FIG. 4.

The invention can be applied to produce a weatherexposed roof surfaceoverlying any sloping support surface 1() but finds greatestapplicability in forming gently sloping roofs having pitches within thegeneral range about 6 to l2. It will be described as applied to theproduction of tiles forming a Bermuda-type or shingleelfect roof,usually over conventional roof sheathing 11 suggested in FIGS. 3 and 5.

The roof should be made waterproof before casting the tiles as thelatter are not relied upon for water tightness. Referring particularlyto FIG. 3 it is preferable to coat the roof sheathing 11 with severallayers of ahphalt mopped roofing felt 22 for Waterproofness. The surfaceis then preferably lightly coatedwith aggregate 13 applied to anasphalt, pitchor plastic-mopped surface of the roofing felt 12 toprovide a knobby support surface for the tiles. In the preferredpractice somewhat at par ticles of ore or light-weight material areused, desirably particles that will not puncture the felt 12 when walkedupon before the tiles are cast.. Pea-size gravel vmay be employed as theaggregate but in all instances it is desirable to employ generally roundgravel particles as distinct from particles having sharp edges whichmight tend to cut the roong felt 12. The aggregate particles are-sprinkled on the soft asphalt so that the lower portions of theparticles embed therein and the upper portions remain exposed. It shouldbe understood however that the invention comprehends the pouring `of thetiles on any knobby surface whether made in this manner or whethercontaining other undulations made for example by scratching, scoring orserrating a surface. Theplatercast cementitious .material adheres to theknobby surface and the cementitious material at the bottom of the tilewill have crests and valleys conforming to the valleys and crests of theknobby surface. This anchoring aids the weight of the cast tiles inmaintaining same in position without other attachment.

In the preferred practice of the invention precast peripheral tiles 15are suitably attached in slightly spaced relationship in anyconventional manner to the thus-prepared support surface 10 along itssides and bottom. Some of these tiles are designated by the letters a,b, c and a', b', and c for later reference. A row of precast ridge tiles16 can also be applied near the roof ridge between the tiles a and a orthese can be cast in place by use of the pouring forms of the inventionif desired. Precast tiles are usually applied at gables, eaves andvalleys of a roof.

These precast tiles may be of the same cross-sectional shape as thetiles to be cast but for uniformity of texture it is preferred that theprecast tiles be thinner and later covered by a layer of thecementitious material. The invention will be described with reference tothe casting of tiles that are about 2" thick at the lower edge and about1" thick at the upper edge although it should be understood that thesedimensions are merely exemplary and that tiles of various uniform ortapering thicknesses can be cast by use of the invention. With tiles ofsuch exemplified height the precast peripheral tiles `15 and 16 may beof a thickness at least 1A less, providing a rough overlay surface onwhich the cementitious material can be poured and adhered to build upthe height of the peripheral tiles to that of the cast tiles. Theperipheral tiles 15 may be of uniform length but are staggered in lengthin the embodiment of FIG. 1.

-The cast tiles of the invention are progressively cast in lateralcourses, starting at or near the top of the roof. A straight orclosed-end pouring form 18, illustrated in FIG. 2, is used to form mostof the tiles in a course starting at either end, the last tile of thecourse being formed by a pouring form of the type suggested in FIG. 4.The invention will be described with reference to a sequence in whichthe pouring is started in a left-hand area 19 of a lateral band 20 justbelow the peripheral tiles 16 and progressing through areas 21, 22, etc.To a right-hand area 23 of the band 20. Lower courses are cast in thesame direction as the rst or upper course.

Various cementitious materials can be employed in casting the tilesdepending upon the desired weight, texture, porosity, etc. of theultimate tile. It is preferred that the cementitious material shouldassume an initial set or become form-retaining in a relatively shortperiod of time so that the pouring form can be lifted rather promptlyand moved to an adjoining area of the band being covered. A cementitiousmaterial that has been found very satisfactory is made by mixing one bagof Portland cement, four pounds of asbestos floats, and about two bagsof aggregate. The latter may be a conventional sand-rock aggregate ifheavy tiles are desired or may be a lightweight aggregate such asperlite, shale, vermiculite, etc. for tiles of lesser weight. 'Iheasbestos floats (nely subdivided asbestos) serve to give the mixturemore body and ability to maintain its shape when the pouring form isremoved. They also permit pumping of the cementitious material atstilfer consistency if this type of placement is desired. It should beunderstood however that binders other than Portland cement can be used,e.g., foam concretes alone r with other aggregates, plastics alone orwith other aggregates, etc.

Referring particularly to FIGS. 2 and 3, the pouring form 18 includes anupper upright form member 24 and a lower upright form member 25 held inparallel spaced relation by means to be described and providing castingspaces 26 therebetween. The form 18 is somewhat foreshortened in FIG. 2for purpose of illustration. Commonly each casting space 26 will be of alength substantially greater than its width, eg., a form 18 may be of alength of 48-72 or more with a width of about 10-14.

The upper form member 24 is shown as formed of heavy sheet metal bent toform an upright portion 24a and a flange portion 24b. This upper formmember provides a downwardly facing scoring edge 27 which may bestraight or serrated to contact the knobby surface of the slopingsupport surface but which is preferably spaced a slight distancethereabove by suitable support means spaced from each other along. thelength of the upper form member 24 as suggested in FIGS. l and 2.

Functioning for this purpose and to space the members 24 and 25 andoutline the casting spaces 26 are two transverse end form members 28 and29 and one or more intermediate form members 30 welded to or otherwisejoining and spacing the form members 24 and 25. At least the upper andlower ends of the lower edge of each of the form members 28, 29 and 30engage the knobby surface to support the form 18 with the scoring edge27 slightly above the knobby surface for a purpose to be described. Inthe illustrated embodiment the lower edge of each of the form members28, 29 and 30 is in a straight line to engage the knobby surfacethroughout the length of such form member. The form members 28, 29 and30 bound the lateral sides of the casting spaces 26 and are of a shapesubstantially corresponding to the cross-sectional shape of the desiredtile. The top of each such form member 28, 29 and 30 provides a screedsurface 33.

The lower form member 25 is shown as a length of angle iron welded orotherwise secured to the end form members 28 and 29 so that its lowerflange is angled slightly with respect to the screed surfaces 33 andsupport surface 10, see FIG. 3, Support means are provided spaced fromeach other along this ange to hold it above the surface 10 to provide aspill-out space 36 between a spill-out edge 37 of the flange and thesupport surface 10 for a purpose to be described. The end andintermediate form members 28, 29 and 30 function as such a supportmeans. The spill-out space 36 is of uniform height throughout itslength, preferably about half or somewhat less than half the thicknessof the desired tile at its lower or thicker end. Handles 38 and 39 maybe respectively welded to the upper and lower form members 24 and 25 thehandle 39 preferably angling forwardly of the lower form member forbetter operation of a screed utilized in a manner to be later described.

In addition to the straight or closed-end pouring form described abovethe invention preferably includes a terminal pouring form 40, shown inFIG. 4, used to pour the terminal tile of a course adjoining one of theperimeter or peripheral tiles such as b. This terminal pouring formincludes upper and lower form members 44 and 45 spaced to dene a castingspace 46 therebetween which is here not divided.

The upper form member provides an upright portion 44a and a flangeportion 44b the former terminating in a downwardly facing scoring edge47. Like the scoring edge 27, the edge 47 may contact the knobby surfaceof the sloping support surface 10 but is preferably spaced a slightdistance thereabove by suitable support means spaced from each otheralong the length of the pouring form 40 as suggested in FIGS. 4 and 5.Functioning for this purpose at one end of the pouring form is atransverse end form member 49 welded to or otherwise joining and spacingthe form members 44 and 45. At least the upper and lower ends of thelower edge of the end form member 49 engage the knobby surface tosupport the scoring edge 47 a small distance thereabove. In theillustrated embodiment the lower edge of the member 49 lies in astraight line to engage the knobby surface throughout its length.Functioning to support the other end of the scoring edge is a leg 51.

The end form member 49 closes one end of the casting space 46 and is ofa shape substantially corresponding to the cross sectional shape of thedesired tile. The top of this member 49 provides a screed surface 53.

As before, the lower form member 45 is shown as a length of angle ironwith its lower flange angled with respect to the screed surface 53.Suitable support means provide a spill-out space 56 between a spill-outedge 57 of the flange. The form member 49 functions as such a supportmeans at one end of the pouring form 40. At the other or open end ofthis form a leg 58 serves as a support and is of such height as to makethe spillout space 56 of uniform height throughout its length.

Toward the open end of the pouring form 40 the upper and lower formmembers 44 and 45 are secured to and spaced by a transverse spacingstructure 60 comprising uprights 61 joined by an angle iron member 62and a member 63. The spacing structure 60 is preferably disposedcompletely above the casting space 46 so as not to obstruct the open endthereof. It preferably angles away from the end form member 49, e.g.,leftward from the left end of the form members 44 and 45, although thisis not absolutely essential. The angle iron member 62 may serve as ahandle to aid in the lifting and moving of the pouring form 20 as mayalso handles 64 and 65 respectively welded to the upper and lower formmembers 44 and 45.

Between the end form member 49 and the spacing structure 60 is a screedmember having an upper screed surface 67 parallel to and of the sameheight above said support surface as the screed surface 53 of the endform member 49. This screed member is preferably in the form of a tautwire 69 having one end anchored to the lower form member 45 by a screw70. The other end extends through an opening of the upper form member 44drilled at the appropriate height and is maintained taut by beingthreaded through an opening of the flange por- .5 tion 44h around whichit is looped to be secured by a screw 71. The wire 69 is stronglytensioned in its section traversing the casting space 46 and is easilyreplaced if broken.

In operation the straight or closedend pouring form 18 of FIG. 2 isfirst positioned over the left-hand areas 19, 21 and 22 of the lateralband 20. If desired it can straddle the perimeter tile b to cast a capor surface layer thereon. The upright portion 24a of the upper formmember abuts against and is aligned by the lower edges of the previouslylaid upper course of tiles, here the peripheral tiles indicated at a andby the numeral 16.

In this position an amount of cementitious material is poured, pumped orotherwise placed in the casting spaces 26, preferably to a localizedlevel above the screed surfaces 33. A fiat screed, indicated by thedotted lines 75 of FIG. 3, is then drawn downward along the screedsurfaces 33. This determines the top surface of the three tiles andapplies pressure to the cementitious material forcing the excess throughthe spill-out space 36 to form a spill-out portion 77 extendingdownwardly into the next lower laterial band with irregular butprogressively decreasing thickness. This spill-out portion 77 aids insupporting the thick ends of the tiles when the form is later lifted andserves other desirable functions. The tiles in the lower or second bandare subsequently cast over the spill-out portion 77. The tiles will bedivided by the members 30 and the right-hand end of the last tile willbe shaped by the end form member 29. lf some of the cementitiousmaterial exudes between the lower edge of the end form member 29 and thesupport surface 10 or if this member provides a spill-out space similarto the space 36, the next cast tile will overlay the spill-out portion.

Several of the pouring forms 18 can be positioned endto-end along thecourse and can be filled in sequence, the first-filled form being liftedfirst and placed in a succeeding position. In this way the entire coursecan be progressively cast up to the last or right-hand area 23, which iscast by use of the pouring form 40 of FIG. 4. This pouring form permitscasting of the last tile to fill the area 23 which is usually of alength greater or less than the previously cast tiles. It can bepositioned with its end form member 49 abutting the perimeter tile b andwith its legs 51 and 58 straddling a previously cast tile. The castingspace 46 is then filled, the left-hand end of the resulting tile beingformed against the end of the last cast tile produced by the pouringform 18 of FIG. 2. In casting the last tile of the course the end formmember 29 may abut the precast peripheral tile b' either at its inneredge (if no cap is to be poured thereon) or its outer edge (if such capis to be poured simultaneously with the last cast tile ofthe course).Irrespective ofthe space between the previously cast title and theperipheral tile b the intervening space will be spanned by the formmembers 44 and 45 which can straddle any portion of such previously casttile. The last cast tile of any course may thus be of any length andwill lill the remaining space up to the peripheral tile b.

When the pouring form 40 is lifted after casting of the last tile of acourse the end form member 49, if adjacent the inner edge of the precasttile b', will leave a narrow space or score line separating the castmaterial and the precast tile. It is desirable to form similar narrowspaces or score lines at the junction of such last cast tile and itspredecessor. In this connection at a suitable time after pouring asuitable scoring tool may be pressed into the cast material to the depthof the support surface or slighly thereabove. This may also be done atthe junctions of earlier-poured tiles of the course. If desired eachunitarily cast tile may be similarly scored at intermediate positionsalong its length to provide a desired pattern.

In forming the next lower course of tiles the pouring form 18 abuts orstraddles the precast tile c, the tiles being cast in sequence asbefore. The upper form member 24 abuts, against the lower edge or edgesof the tile or tiles of the previously-cast course. The scoring edge 27of this upper form member automatically penetrates the spill-out portion77 of the previously-cast tiles of the adjacent upper course, thusautomatically scoring this junction to a position slightly above thesupporting surface 10. If scoring is not completely to the supportsurface the shrinkage of the cementitious material when hardened willcrack any joining portion of the tiles of the ltwo courses so that theyremain independent olf each other 1n use.

The tiles of a previously cast course thus align the form of the nextcourse so that when the lowest course of the roof is poured adjacent theperipheral tiles 15 at the eave line all courses will have parallel andstraight shadow lines. If the height of the spill-out spaces 36 and 56is made equal to or less than the height of the precast eave tiles 15 attheir narrow sides there will be no spill-out portion 77 on suchperipheral eave tiles 15. However the pouring form 18 can be used topour a cap of the cementitious material on these precast eave tiles ifthey are of substandard height.

The roof may be capped by a ridge cap 8 shown in FIG. l. This may becast in sections by conventional forms.

The resulting roof is in effect composed of a plurality of independenttiles having lower surfaces corresponding to the undulations of theknobby surface on which they are poured. They need not be otherwisesecured to the support structure of the roof as their weight and theiradhesion to the knobby surface suices to maintain them in position.These tiles can independently expand and contract without danger oftearing the waterproof layer formed by the felt 12. They can be left intheir natural state or they can be painted. The finished roof will havedistinct shadow lines in view of the fact that the thinner upper edge ofeach tile is adjacent the thicker lower edge of the tiles of an adjacentupper course. The resulting roof has excellent insulation propertiesbecause of the thickness of the cementitious material. It is aspermanent as the waterproof -felting 12 and greatly increases the lifeof the latter in protecting it from the sun.

Various changes and modifications will be apparent to those skilled inthe art from the foregoing description and are within the scope of theappended claims.

I claim:

1. A method of forming a tiled roof surface of cementitious material ona sloping support surface, including the steps of:

(a) casting on an upper portion of said sloping support surface an uppertile of cementitious material having an upper edge and having a loweredge spaced downwardly along said sloping support surface from saidupper edge of said upper tile;

(b) restraining the upper portion of the cementitious material of saidlower edge of said upper tile against movement downwardly along saidsloping support surface while simultaneously permitting cementitiousmaterial below said upper portion of said lower edge of said upper tileto ow downwardly along said sloping support surface to form a lower,spillout portion;

(c) removing the restraint against movement of said upper portion ofsaid lower edge of said upper tile downwardly along said sloping supportsurface after said lower edge of said upper tile has set suiciently tosubstantially retain its cast shape; and

(d) casting on a lower portion of said sloping support surface, spaceddownwardly along said sloping support surface from said upper portionthereof, a lower tile of cementitious material having an upper edgeoverlying said lower, spill-out portion of said upper tile and having alower edge spaced downwardly along said sloping support surface lfromsaid upper edge of said lower tile. 2. A method of forming a tiled roofsur-face of cementitious material on a sloping support surface,including the steps of:

(a) casting on an upper portion of said sloping support surface an uppertile of cementitious material having a thin upper edge and having athick lower edge spaced downwardly along said sloping support surfacefrom said upper edge of said upper tile;

(b) restraining the upper portion of the cementitious material of saidlower edge of said upper tile against movement downwardly along saidsloping support surface while simultaneously permitting cementitiousmaterial below said upper portion of said lower edge of said upper tileto flow downwardly along said sloping support surface to form a lower,spill-out portion;

(c) removing the restraint against movement of said upper portion ofsaid lower edge of said upper tile downwardly along said sloping supportsurface after said lower edge of said upper tile has set su'iciently tosubstantially retain its cast shape;

(d) casting on a lower portion of said sloping support surface, spaceddownwardly along said sloping support surface from said upper portionthereof, a lower tile of cementitious material having a thin upper edgeoverlying said lower, spill-out portion of said upper tile and having athick lower edge spaced edge of said upper tile and said upper edge ofsaid lower tile; and

(f) scoring said lower tile, and at least part of the underlying lower,spill-out portion of said upper tile along a horizontal line at thejunction of said lower edge of said upper tile and said upper edge ofsaid lower tile, and to a depth close to said sloping support surface.

4. A method of forming a tiled roof surface of cemen- 10 titiousmaterial on a sloping support surface, including the steps of:

(a) securing precast peripheral tiles in abutting relationship along thesides and bottom of said support surface thereby leaving a centralportion of said support surface bounded by such peripheral tiles saidcentral portion including a substantial area of said support surface;

(b) subsequently sequentially casting tiles of cementitious material inlateral courses with some of the cast tiles being immediately adjacentsaid precast peripheral tiles to substantially lill said central portionwith said sequentially cast tiles; and

(c) utilizing such precast tiles to align at least some of thesequentially cast tiles therewith.

5. A method of forming a tiled roof surface of cementitious material ona sloping support surface, including the steps of:

(a) securing precast peripheral tiles along the sides and bottom of saidsupport surface thereby leaving downwardly along said sloping supportsurface from a central portion of said support surface bounded saidupper edge of said lower tile; and by such peripheral tiles;

(e) said upper edge of said lower tile, including the (b) subsequentlycasting tiles and spill-out portions of underlying lower, spill-outportion of said upper tile, cementitious material in lateral courses tosubstanbeing cast with a thickness less than the thickness tially llsaid central portion, said spill-out portions of said lower edge of saidupper tile to provide a extending downwardly from the lower edges of thehorizontal shadow line at the junction of said lower tiles in each ofsaid lateral courses and supporting edge of said upper tile and saidupper edge of said said lower edges of said tiles against movement lowertile. downwardly along said sloping support surface; and

3. A method of forming a tiled roofl surface of cemen- (c) using suchprecast tiles to align at least some of titious material on a slopingsupport sur-face, including the steps of (a) casting on an upper portionof said sloping support surface an upper tile of cementitious materialhaving the subsequently cast tiles therewith. 6. A method of forming atiled roof surface of cementitious material on a sloping supportsurface, including the steps of:

a thin upper edge and having a thick lower edge spaced downwardly alongsaid sloping support surface from said upper edge of said upper tile;

(b) restraining the upper portion of the cementitious material of saidlower edge of said upper tile against movement downwardly along saidsloping support surface while simultaneously permitting cementitiousmaterial below said upper portion of said lower edge of said upper tileto flow downwardly along said sloping support surface to form a lower,spill-out portion;

(c) removing the restraint against movement of said upper portion ofsaid lower edge of said upper tile downwardly along said sloping supportsurface after said lower edge of said upper tile has set sufficiently tosubstantially retain its cast shape;

(d) casting on a lower portion of said sloping support surface, spaceddownwardly along said sloping support surface from said upper portionthereof, a lower (a) securing precast peripheral tiles along the sidesand bottom of said support surface thereby leaving a central portion ofsaid support surface bounded by such peripheral tiles;

(b) casting a top row of tiles and spill-out portions on said centralportion to form a top lateral course, said spill-out portions being atthe lower edges of such cast tiles and of lesser height than such loweredges;

(c) casting a next-lower row of tiles and spill-out portions on saidcentral portion with the tops of such tiles overlying the spill-outportions of the tiles of said top row, to form a next-lower lateralcourse; and

(d) casting additional next-lower rows of tiles on the remaining area ofsaid central portion to form additional lateral courses substantiallyfilling such remaimng area.

References Cited by the Examiner tile of cementitious material having athin upper UNITED STATES PATENTS edge overlying said lower, spill-outportion of said (e) said upper edge of said lower tile, including theunderlying lower, spill-out portion of said upper tile, being cast witha thickness less than the thickness of said lower edge of said uppertile to provide a horizontal shadow line at the junction of said lowerROBERT F. WHITE, Primary Examiner.

ALEXANDER H. BRODMERKEL, Examiner,

1. A METHOD OF FORMING A TILED ROOF SURFACE OF CEMENTITIOUS MATERIAL ONASLOPING SUPPORT SURFACE, INCLUDING THE STEPS OF: (A) CASTING ON AN UPPERPORTION OF SAID SLOPING SUPPORT SURFACE AN UPPER TILE OF CEMENTITIOUSMATERIAL HAVING AN UPPER EDGE AND HAVING A LOWER EDGE SPACED DOWNWARDLYALONG SAID SLOPING SUPPORT SURFACE FROM SAID UPPER EDGE OF SAID UPPERTILE; (B) RESTRAINING THE UPER PORTION OF THE CEMENTITIOUS MATERIAL OFSAID LOWER EDGE OF SAID UPPER TILE AGAINST MOVEMENT DOWNWARDLY ALONGSAID SLOPING SUPPORT SURFACE WHILE SIMULTANEOUSLY PERMITTINGCEMENTITIOUS MATERIAL BELOW SAID UPER PORTION OF SAID LOWER EDGE OF SAIDUPPER TILE TO FLOW DOWNWARDLY ALONG SAID SLOPING SUPPORT SURFACE TO FORMA LOWER, SPILLOUT PORTION; (C) REMOVING THE RESTRAINT AGAINST MOVEMENTOF SAID UPPER PORTION OF SAID LOWER EDGE OF SAID UPPER TILE DOWNWARDLYALONG SAID SLOPING SUPPORT SURFACE AFTER SAID LOWER EDGE OF SAID UPPERTILE HAS SET SUFFICIENTLY TO SUBSTANTIALLY RETAIN ITS CAST SHAPE; AND(D) CASTING ON A LOWER PORTIN OF SAID SLOPING SUPPORT SURFACE, SPACEDDOWNWARDLY ALONG SAID SLOPING SUPPORT SURFACE FROM SAID UPPER PORTIONTHEREOF, A LOWER TILE OF CEMENTITIOUS MATERIAL HAVING AN UPPER EDGEOVERLYING SAID LOWER, SPILL-OUT PORTION OF SAID UPPER TILE AND HAVING ALOWER EDGE SPACED DOWNWARDLY ALONG SAID SLOPING SUPPORT SURFACE FROMSAID UPPER EDGE OF SAID LOWER TILE.